Tesla's Third-Gen Optimus Unexpectedly Leaked: Redesigned Exterior Better Suited for Factory Use

The design of Tesla's (TSLA-US) third-generation humanoid robot Optimus has unexpectedly surfaced. A robotics enthusiast extracted unreleased images from Tesla’s Android application package, including renderings labeled 'third generation' (gen3), as well as side-by-side comparison visuals with the Optimus 2.5 model. Judging from the exterior changes, the new mechanical structure is more fully enclosed, appearing better suited for tasks on factory production lines.

X user @wholemars posted this discovery on Tuesday, though the post has since been deleted. The related images are not conceptual sketches or fan-made renderings, but rather assets embedded within Tesla’s publicly distributed application package.

However, Tesla has not yet officially unveiled the complete design of the third-generation Optimus. What is currently visible externally consists solely of images extracted from the app.

Compared to the 2.5 version, the third-gen Optimus features a cleaner exterior. Images show that previously exposed mechanical linkages in the lower legs are now covered with matte black shells. The torso adopts a smoother, champagne gold design. Flexible covers have also been added where the torso meets the thighs, sealing off the joints.

These modifications reduce direct exposure of moving parts, helping prevent debris or unintended contact from affecting bearings and joints. Based on the viewing angle of the images, the third-gen design appears to place greater emphasis on factory production environments than previous versions. However, actual operational capabilities or final mass-production specifications cannot be confirmed based solely on exterior visuals.

Tesla has not announced an official release date for the third-generation Optimus. Elon Musk stated in March this year that the third-gen Optimus had already entered trial operation, though some finishing work remains before formal launch.

He also noted that Tesla prefers to keep designs under wraps until closer to mass production, partly to avoid imitation by competitors. This leak of app assets has led to the premature exposure of the next-generation appearance before official unveiling.

On the production front, drone survey footage indicates that the steel framework for Tesla’s Texas Gigafactory—planned for Optimus mass production—is nearing completion. According to current plans, the facility is set to begin operations in 2027, targeting an annual output of 10 million units.

This past summer, Tesla dismantled the Model S and Model X production lines at its Fremont, California factory, converting them into Optimus production lines with a target annual capacity of 1 million units. In addition to facility upgrades, new developments in supply chain preparations have also emerged.

According to earlier reports by Cailian Press, Tesla placed a bulk order of approximately 5,000 Optimus units with core suppliers in early September. More recently, Tesla has begun factory audits of Ningbo-based listed companies including Top Group, Sanhua Intelligent Controls, and Joyson Electronics.

From production line renovations and supply chain activities to the recent exposure of the third-gen exterior, preparations for Optimus mass production are gradually coming into view—though the specific launch timeline awaits Tesla’s official announcement.